CÔNG TY CỔ PHẦN CƠ KHÍ – ĐIỆN LỮ GIA

LU GIA MECHANNICAL – ELECTRIC JOINT STOCK COMPANY

---------o0o--------
ASSEMBLY ERECTION Operation and
maintenance manual
for
lighting Masts
(3-point SUSPENSION system)

LIGHTING & URBAN EQUIPMENT C OMPANY.,LTD

ADDRESS : 70-LUGIA STR.,HO C HI MINH, VIET NAM
ASSEMBLY ERECTION OPERATION AND
MAINTENANCE MANUAL

2
 TABLE OF CONTENTS
No
CONTENT Page
.

1 Part I - Introduction 6

2 Part II - Assembly 9

3 Part III - Hoisting wire ropes 11

4 Part IV - Assembly of fixed bracket & hoisting system 17

5 Part V - Erection 22

6 Part VI - Luminaire carriage assembly 25

7 Part VII - Luminaire carriage latching system 28

8 Part VIII - Luminaire and accessories 30

9 Part IX - Maintenance 34

10 Part X - Manufacturer’s information 35

3
 LUGIACO APRON flood lighting MAS
3-point suspention system
Kim thu s? t

N? n c hôp
C O VER PRO TEC TIO N

Dµn c è ®inh
FIXED SYSTEM

C ¸ p n©ng h¹ D8
C ABLE FO R LIFT UP AND DO WN D8
C ¸ p DÑp 6X4mm2 & c ¸ p th«ng tin
PO WER SUPPLY 6x4mm2 (ELEC TRIC AL, INFO RM ATIO N)

Hép ®Êu nèi

J UNTIO N BO X

Dµn ®? n di ®éng
luminaires c a rriage ring

Th©n c ét
ma st body

TÊm c huyÓn
tra nsition plate
Hép gi¶m tèc ,
trôc b¸ nh v?t § i? u khiÓn c Çm tay
reduc tion gear REM O TE penda nt c ontrol
§ éng c ¬ 1.1KW C öa c ét
motor 1,1kw servic e door
B¶ng ®iÖn
elec tric al board

5m

4
 Part I
1.1 - Introduction
This manual has compiled to assist site management with the following:
• Assembly, erection, operation and periodic maintenance of lighting masts
with winch operated raising and lowering equipment.
• Before starting operation, users are recommended to carefully read the instruction.
• Lighting masts floodlighting manufactured by HAPULICO is made based on the structure
of steel section with length suitable for transport and installation.
• Sections of the Mast body and Utilities are manufactured by modern production line with
advanced technology.
• Our engineers had made necessary calculation to gain the comprehensive capacity on mast
structure. A special computer program was used to achieve figures which match the height,
load and wind velocity of polygon section mast.
• Strictly following content of working security is essential during the period of installation,
operation and maintenance.
• Save time, make it easy to deal with the mast if instruction is closely followed.
• The constant development and progress in design and manufacture of the company may
make some actual parts of the mast different from the one in supplied material. The
company holds the rights to modify our production without prior notice.
1.2 - Safety warning
Safe working practices in assembly, erection and operation of the equipment should be
observed at all times.
It is essential that the following procedures are followed when operating the equipment.
1. Mechanical and electricity works must be controlled by qualified and authorized person only.
2. Unauthorized and observation people must keep a safe distance from the mast.
3. During the work, do not stand right under:
- Flood light: including the fixed bracket and mobile luminaire carriage.
- Ground for conducting maintenance.
When work is in progress
The mast controller is at least 5m far from the mast.
4. Mast controllers and observation people must wear safety helmet.
5. Do not use the corrupted metal cable.
6. Pulling cable and installing equipment with glove.
7. Using lifeline is a must when being on the flood light.
8. Do not use over-limitation safety equipments.
9. Do not operate in strong wind condition.
10. Do not use the similar replacing equipments. Use the right-designed equipments

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Part II – COLUMN ASSEMBLY
2.1 PACKING, SITE REQUIREMENT AND UNLOADING

2.2 ASSEMBLY OF COLUMN SECTIONS

2.1 PACKING, SIT REQUIREMENT AND UNLODING

1. Column sections are co-axially packed inside each other for ease of handing in transport
2. The fixed bracket assembly and accessories are packet in separate containers.
3. The winch is supplied mounted on its mounting bracket ready for bolting into the mast.
4. The equipment required at site will be :
a. A mobile crane of sufficient capacity and lift height.
b. Suitable slings.
c. A quantity of wedges and timber for packing, to suit the number of column section
d. Two pull lift devices with a minimum capacity of 4 tonnes
e. A crowbar, a sledge hammer...
f. A quantity of rubber based grey paint or linseed oil to suit the number of joints.
g. A crew of 4 men are normally required to carry out the assembly and erection, in
addition to the crane crew.
5. Unload the column sections onto the packing on the ground in order of assembly and in line
so that the center of gravity will be adjaccent to the column foundation when assembled,
making due allowance for the joint overlap. This will minimise crane handling when erecting
the column (Figure 2.1).

K hung mãng cét

§ Õ cét C öa thao t¸ c

CG C ¸ c ®o¹ n cét

(Figure 2.1)

(Figure 2.1).

2.2 ASSEMBLY OF COLUMN SECTIONS

1. Arrange the base section onto the packing with the access opening on the top and levelled so
that the axis of the column section will be horizontal. The height of the packing must be

6
 compatible with the base plate and the fixed bracket dimentions so that both will be clear of
the ground when assembled.
2. Make sure that the base plate is wedge to prevent rotation.
3. Check that the packing under the arranged sections is a minimum of 300mm clear of the end
of the slip joint length ( L ) (Figure 2.2) to allow for column during assembly.

§Ơ cét 300
L

(figure 2.2)

4. Lubrication for the slip joints is provided by rubber based paint or linseed oil applied to the
column sections to be joined as follows (Figure 2.3)
a. The external suface of the lower column section is coated for approximatetely 75% of
the slip joint length from the end of the section.The minimum length of the slip joint is
marked on the male section of the column joint, with red coloured paint.
b. The internal surface of the upper column section is coated for approximately 75% of the
slip joint length leaving the first 25 % of slip joint length clear.

7
 0.25L 0.75L 0.25L 0.75L

ChiÒu dµi mèi ghÐp khi l¾p = L

(Figure 2.3)

5. To facilitate, the internal surface can be coated while the section is resting on the packing,
prior to slinging to the required assembly height.
6. Do not use oil or grease for assembly lubrication as this may lead to a detrimental appearance
if runs or drips are formed.
7. Sling the section for assembly at its centre of gravity and engage the sections, making sure
that the centre line of the column is correctly aligned in the horizontal and vertical planes.
8. While installing the pull winchs into 2 sides of the column under the close supervision pull
winch will move unanimously to ensure column sections to be fitted synchronously according
to the column axis.(figure 2.4)

(Figure 2.4)
8
 9. During operation perform step. 8 the external surface of the slip joint can be hammered
using a wooden block and a sledge hammer, to assist in achieving a good joint. Do not
hammer directly on the galvanised surface. The length of the slip joint “L” according to
design.
10. Misalignment of the sections for any reason may lead to jamming, which will prevent good
telescoping of the joint any may be difficult to rectify.
11. Compare of theoretical slip joint length with the actual slip joint length, and if necessary
continue to apply pressure as describel in 9 above until at least the minimum nominated
dimension is obtained.
12. Continue assembly process of column step. 3. Always check straight level of the column
sections.
13. When the final section of the column is in plate, the packing must be arrange so that there is
at least 1300mm to enable fitting of the fixed bracket at a later stage.
Part III – HOISTING WIRE ROPES
3.1 WIRE ROPES
3.2 CORRECT PROCEDURES
3.1 WIRE ROPES

1. Hoisting wire ropes are stainless steel supplied by LUGIACO

2. Do not substitute any other construction of wire ropes.
3. Minimum breaking strain:
a. 4259 kg for 8mm diameter.
b. 6680 kg for 12mm diameter.

3.2 CORRECT PROCEDURES FOR MAKING UP SUSPENSION WIRE ROPES

1. Disconnect the cable as illustrated in pictures 3.1 and 3.2.

2. If cable is wrongly disconnected, it will be tied or twisted. Though the cable surface is
strained but in fact, its inner structure was mixed.
3. If that tied/twisted positions are strained, then at the position, length and quality of cable
will be reduced, life expectance and safety of cable will seriously lessen.
4. Do not straighten the tied or twisted section. Replacement of new one is essential in the
case.
5. Types of
twisted
section.

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 a) Picture 3.3 & 3.4: Twisted on the left or right due to wrong disconnection.
b) Picture 3.5 & 3.6: Illustration of the right and left twisted (the usage of this is
absolutely forbidden, it is obligatory to replace with the new one).
c) Picture 3.7 & 3.8: Illustration of straightening the right/left twisted (the usage of this is
absolutely forbidden, it is obligatory to replace with the new one).
6. The fastening clams must be put in position. U-fastening clams must closely touch the wire
and be located from the first position (picture 3.9).

Picture 3.9
7. Wrongly cliping (3.10) will affect the strength of the wire, to repair this, it is essential to
make the fastening clams in series (3.11).

Picture 3.10

10
 Picture 3.11
8. The number of fastening clams are required as in the following table:

Cable radius (mm) Φ8 Φ 12

Number of fastening clams 03
03
(nos)
Distance to the center (mm) 45 60

Part IV – ASSEMBLY OF FIXED BRACKET AND HOISTING SYSTEM

4.1 ASSEMBLY OF HOISTING WIRE ROPES TO THE TRANSMISSION SET

4.2 ASSEMBLY OF TRANSMISSION SET

4.3 ELECTRICAL POWER CABLE ASSEMBLY

4.4 POSITIONING THE TRANSMISSION SET

4.5 ASSEMBLY OF FIXED BRACKET

4.1 WIRE ROPES

- Prepare the 3 hoisting wire ropes to the same length and mark (refer figure 4.1)

Lc

§ iÓm ®¸nh dÊu

(Figure 4.1)

Lc : Length of wire rope

Length of wire rope in the following table

Mast size Mast 25 m Mast 30 m Mast 35 m Mast 40 m

Lc (mm) 24500 29500 34400 38900

4.2 ASSEMBLY OF TRANSMISSION SET

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1. Feed the pull through rope into the mast through the door opening and attach the other end to
the base plate (Figure 4.2).

(Figure 4.2)
2. Tie the other end of the rope to the transmission set (Possitioning (1) Figure 4.3)
3. Tie 3 hanging rope to the transmission set (Possitioning (2) Figure 4.3) place a wooden block
in the column (3) (Figure 4.4) to protect the hanging rope and power cable

(Figure 4.3)

(Figure 4.4)
4. Lay the cables out perfectly straight to avoid any kinks and attach. Pull the transmission set
into column.
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 5. If it is not possible to lay the cables out straight thay may be coiled as shown in (Figure 4.5)

(Figure 4.5)

Note : In order to avoid faulty in the assembly process it requires to distinguish electric cable and
hanging cable with a colour plaster, each kind with one colour
Ensure to assemble according to right direction of electric cable and hanging cable from
transmission set to puly (Figure 4.6)

3
5
(Figure 4.6)
Include :
A : Puly hanging rope
B : Puly electric cable
3 : Hanging rope
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 5 : Electric cable
4.3 ELECTRICAL POWER CABLE ASSEMBLY

1. One, two or three power cables may be supplied subject to the power required for the
luminaires.
2. Identify each power cable using coloured adhesive tape.
3. Each power cable (5) is placed facing a hoisting wire rope (3) (Figure 6)
4. Fasten the electric cable in to the tranmission set with clamp plates (4). Note electric cable (5)
must be let unstraight until the hanging cable is straight.
5. Leave a distance of 2m metre between the transmission set and cable end (Figure 4.7)

2000mm

5 4

(Figure 4.7)

4.4 POSITIONING THE TRANSMISSION SET

1. When the wire ropes and power cables are correctly aligned, pull the transmission set through
the mast until the 2m above the top of the door opening.
2. Wire ropes and electrical cables must project outside the top of the mast, for it to pass through
the fixed bracket when fitted.
Note :
1. Bolt to fit winch bracket and machine is M16 (Page 27)
2. Mechenical transmission system includes machine, cable drum and chain transmission set were
assembled and adjusted at the bottom of column (Figure 4.8).

14
 TÊmchuyÓn
transitionplate

Hép gi¶mtèc,
trôc b¸nhv?
t
reductiongear
§éng c¬1.1KW
motor 1,1kw
Cöa cé t
B¶ng ®iÖn serv ice doo r
electrical board

(Figure 4.8)

15
4.5 ASSEMBLY OF FIXED BRACKET

1. Assemble the fixed bracket to the stub using M16 bolts (Refer page 27)
2. Remove the fixed bracket cover (Figure 4.9).
3. Pass the hanging rope (to raise fixed bracket with crane) with position one among three age of
fixed bracket according to vertical (Figure 4.9)

(Figure 4.9
4. Feed (about 2m) hanging cable and electrical cable through fixed bracket.
5. Slide fixed bracket to the top of mast (Figure 4.10)

(Figure 4.10)

16
6. Pass the wire ropes and electrical cable above pulies (Figure 4.11) (Note : Separate hanging
ropes and electrical cable with cable dividing set in the fixed bracket and don’t let the cable
attach).

(Figure 4.11)

17
 7. Pull hanging rope and electrical cable to the bottom of base plate and bind together (Note :
Don’t let the cable be twisted)

Part V – ERECTION

5.1 COLUMN FOUNDATIONS

5.2 PROCEDURE FOR ERECTION

5.3 BOLT TORQUE TABLE

5.1 COLUMN FOUNDATIONS

1. The column foundation, supplied by others, must be designed by competent civil engineers to
suit the soil conditions at the location of the column.
2. Before pouring concrete for the foundation it is recommended that templates be used to
ensure that’s the bolts will be correctly centred and vertical. The protruding portion of the
bolts should be coated with grease and protected by a cap.
5.2 PROCEDURE FOR ERECTION

1. Thread nuts over all the anchor bolts so that they will be under the column base plate and
clear of the top of the concrete by approximately 15-20mm.
2. Adjust two pairs of nuts diametrically opposite at 90 degrees so that thay are 15-20mm higher
than the remainder and level with each other. These four nuts will provide a means of
obtaining vertical alignment by adjustment (Figure 5.1)

160
15-20
15-20

(Figure 5.1)

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3. The fifting point will be several metres further up the column than the centre of gravity. At
the lifting point a suiteble sling is applied from which two “Pull-lift” or similar divices, one
each side of the column, are arranged with the lower end anchored at the base plate. These
“Pull-Lift” devices are tensioned to avoid a possible seperation of slip joint, and to prevent
the sling from slipping up the column (Figure 5.2)
4. Before lifting the column, mark the base plate and foundation to ensure that the fixed bracket
assembly and lighting array are correctly aligned.
5. If necessary, rotate the column on the packing prior to lifting to facilitate the alignment.

19
 (Figure 5.2)
6. When the column is located over the bolts, fit washers and nuts to the anchor bolts. Adjust the
4 nuts on the underside of the base plate which are apaced at 90 degrees and are 15-20mm
above the others, using the weight of the column to facilitate its vertical adjustment
7. When the column is vertically aligned tighten all the nuts under the base plate and the
corresponding nuts above. Apply lock nuts to all bolts. Keep the mast suppended on the crane
until this operation is completed. Tension the nuts as specified on the bolt torque table Page
27.
20
 8. Fill the space under the base plate with grout and protect exposed parts of the anchor bolts
with bitumen or by other suitable means (Figure 5.3)

Lùc xiƠt ®ai èc

tham kh¶o trang 27

(Figure 5.3)
5.3 BOLT TORQUE TABLE

RECOMMENDED BOLT TORQUE FOR LUGIACO MASTS

21
 FOUNDATION ANCHOR BOLTS FOR COLUMN AND ACCESSORIES
BOLTS
SIZE NUT TORQUE SIZE TORQUE CLAS TORQUE
CLASS CLASS
(mm) (Nm) (mm) (Nm) S (Nm)
M30 4.6 495 M10 5.8 30 8.8 45
M36 4.6 865 M12 5.8 50 8.8 80
M42 4.6 1380 M16 5.8 125 8.8 190
M48 4.6 2065 M20 5.8 245 8.8 375
M56 4.6 3335 M24 5.8 420 8.8 640
M64 4.6 5035
NOTE:

 Foundation anchor bolts are class 4.6

 If high tensile steel foundation bolts are used special anchoring and tensioning techniques must
be follower and specialised. Foundation engineering design is required

 Hexagon head bolt class identification is marked on the head of the bolt.

4.6

 Never use bolts of a class lower than specified.

 When tensioning bolts and nuts, apply the torque wrench to the nut and hold the bolt head with a
spanner to prevent the bolt turning.

Part VI – LUMINAIRE CARRIAGE ASSEMBLE

6.1 PREPARE

6.2 LUMINAIRE CARRIAGE ASSEMBLE

6.1 PREPARE

1. Fit the 3 luminaire carriage support arms into mast body.

2. Installation operation floor above of bracket 0,6m
6.2 LUMINAIRE CARRIAGE ASSEMBLE
1. Parts of luminaire carriage

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 - Luminaire carriage
- Fixed frame
- Support for obstruction lighting
- Support for flood light
- Junction box
- Located frame
- Latch grove
2. Parts of luminaire carriage installation together (refer figure 6.1)

2 7
6

5
4
3
(Figure 6.1)

23
(Figure 6.1)

24
3. Hanging cable installation refer (Figure 6.2)

(Figure 6.2)

25
4. Remove luminaire carriage with hand and check refer (Figure 6.3)

(Figure 6.3)

26
 Part VII – LATCHING OF THE LUMINAIRE CARRIAGE

7.1 POSSITION OF THE LATCH

7.2 CLOSED AND OPEN STATUS OF THE LATCH

7.1 POSSITION OF THE LATCH

1. Latching of the luminaire carriage include 3 latchs arrange refer (Figure 7.1).

(Figure 7.1)

2. Latch (1) may be spun round pin (2) (Figure 7.2)

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 1 2

(Figure 7.2)

7.2 STATUS OF THE LATCH

Status of the latch:
1. “Closed” status: the flood light reaches the mast top, the latch (1) is fixed to the supporter (3)
on the fixed bracket (Figure 7.3)
28
3

(Figure 7.3)

29
2. “Open” status: starting the lowering; the latch (1) leaves the supporter (3) and moves down
(Figure 7.4)

(Figure 7.4)

30
Part VIII – LUMINAIRE CARRIAGE AND ELECTRIC EQUIPMENT SYSTEM

8.1 ADJUSTMENT OF LUMINAIRE CARRIAGE POSSITION OF THE LATCH

8.2 INSTALLATION OF ELECTRIC SYSTEM

8.1 ADJUSTMENT OF LUMINAIRE CARRIAGE

1. Fit the 3 luminaire carriage support arms into mast body. Switch cable drums to raise
luminaire carriage to the lock position, ensuring the stability of 3 latches locked. Fix the
hanging cable.
2. Cheking 3 hanging cables linked to the transmission set, ensuring the strain level
same.
- If the strain level of each cable is the same, lock the cable keeping bolts (3) (4) of
hanging cables.
- If the strain level of cables is different, unfasten bolts (3) (4) on the transmission set to
adjust cables accurately and then fasten (Figure 8.1)

(Figure 8.1)

31
32
 (Figure 8.2)
The Figure 8.2 describle the operation of the switch. The process ends when the pin (1)
contact to the process switch (2).
Part IX- MAINTENANCE

9.1 12 - MONTH MAINTENANCE

9.2 24 - MONTH MAINTENANCE

9.3 REPLACEMENT OF HANGING CABLE

9.4 REPLACEMENT OF ELECTRIC CABLE

9.5 REPLACEMENT OF THE PULLING SLING

9.1 12-month maintenance.

1. Shut down the electric source.
2. Check all the bolts, nuts; tighten the transmission set to see if they are already loosen or
corroded.
3. Check lubricant level in service outlet box. Fill in or replace if necessary.
Hanging and pulling cable.
4. Thoroughly check the outstanding conditions of the pulling sling all the way long from the
winch pulley to the distribution unit.
33
 5. Check all the links between the distribution unit and the sling to see if they are already loosen or
malfunctioned.
6. Check the fastening clams of the electric cables to see if the electric cables already wear
some abrasion and fasten the bolts if necessary.
Equipments inside the Mast
7. Check the plugs and the electric wires to see if they are crooked and broken.
8. Check the connection points of the main panel.
9. Check the earthing wire
10. Connect the motor to the main and lower the lighting frame.
11. All the lights and the switch boxes must be check to detect any possible leakage of the rain
water (this is a crucial requirement).
12. Clean all the pane of the lights and the reflecting surfaces if necessary. It is forbiddance to use
the materials or substances possibly causing scratches to the glass panes of the lights.
13. Disconnect the light bulb and check the holder.
14. Check the electric cable for the damages relating to the ultraviolet rays or other physical
reasons.
15. Check the connection in the connection boxes and at the intermediate connection point.
16. Check the liner around the electric cable.
17. Check the bolts and nuts of the flanges to detect the loosening and fasten if necessary.
18. Check the working condition of the hanging lock.
19. Test the lams.
20. Hoist the lighting frame.
21. Socket the plugs.
Anchor bolts at the foot of the mast.
22. Check the fastening of the nuts.
Note:
23. Take note and report all problems.
9.2 24-month maintenance.
1. check and carry out the maintenance regime for 12-moth period and do some more
subworks as follow:
2. Lower the lighting frame on to the supporters and disassemble it.
3. Unscrew the nuts and bolts connecting the flanges to detect any crook if having.
4. Check the washers for any abrasion, replace with the new one if necessary.
5. Check the outer surface of the electric cable for any abrasion. If so, replace the cables with the
new one.
6. Check the shape of the lighting frame.
9.3 Replacement of the hanging cable.
1. Prepare 1 section of the same sort of sling of which the length is 1m longer than the mast’s
height.
2. Make the loop at each end.
3. Lower the lighting frame onto the supporters.
34
 4. Disconnect the hanging cable from the lighting frame.
5. Cut the old sling at the at the position right above the hanging position.
6. Plait or joint one end of new sling to the just-cut end of the old section.
7. Lower the distribution unit until the end of new section could go inside the mast from the top
hole. Pay attention to keep the other end of new section from not sliding through the top
hole of the mast.
8. Disconnect the new sling and the old one, make the new loop and fasten the new sling to the
distribution unit.
9. Connect the other end the new sling to the lighting frame. Check the working processes of the
lighting frame (it is a must to keep the electric cable from not being tensile).
10. Reset the limit for the traveling of the lighting frame.

Picture 9.1

9.4 Replacement of electric cable

1. Prepare 1 section of the same kind of the old electric cable with 2m longer than the old one.
2. Lower the lighting frame onto the supporters.
3. Disconnect the electric cable from the connection boxes on the lighting frame. Tap one end of
the new cable to the connection box on the lighting frame. The other end will be jointed to
35
 the end of the old cable in order to get it slide into the mast through the top hole. The link
should be firm enough to be able to pull the new cable up into the mast through the top
hole.
4. Hoist the lighting frame to the working position, disassemble the old cable from the fastening
clams.
5. Manually pull the new cable all the way inside the mast and fasten it to the distribution unit by
using the fastening clams (remember that the electric cable is not supposed to bear
any weight of the lighting frame)
6. Remove the old cable and tap the new one of the main panel

Picture 9.2

36
9.5 Replacement of the pulling sling on the pulley winch
1. Disconnect the old sling from the distribution unit.
2. Unroll the old sling from the pulley (keep on pushing the “Down” button on control unit).
3. Get 1 section of the new sling with the same length as the old one.
4. Connect the one end of the new sling to the pulley. Keep on pushing the “Up” button to roll the
sling around the pulley.
5. Make the loop at the other end of new sling then connect it to the distribution unit.
6. Make the necessary adjustment and reset the traveling process of the lighting frame.

37
Part X: Manufacturer’s information
 Refer attached supplier’s catalogue for information
 Company name : LUGIACO
Address : 70- Lu Gia Str., Ho Chi Minh, Vietnam
Tel : +083-9626954/0822433022
Fax : +(84-8)39650012
Email : lugiaco@lugiaco.com.vn
Website : www.lugiaco.com.vn

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